Beneficial use structures
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Solution Overview
Problem
Coal combustion residuals (CCR) pose environmental and storage challenges due to their accumulation in large quantities, requiring innovative and regulatory-compliant methods for their management and utilization, as existing disposal practices are costly and environmentally risky.
Innovation Solution
Development of encapsulated CCR mixes for use in load-bearing structures, roller-compacted concrete, and mine reclamation, which incorporate high percentages of CCR as cement replacements, combined with water and additives to enhance strength, durability, and reduce leaching potential, adhering to EPA guidelines for beneficial use, thereby minimizing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If CCR is stored in traditional disposal methods (landfills and impoundments), then environmental risk and storage cost are reduced, but the material accumulates in vast quantities and creates ongoing environmental hazards
Solution Approach 1:
The patent applies this principle by transforming CCR from a harmful waste material into a beneficial construction material. The encapsulated CCR mixes are used to create load-bearing structures, roller-compacted concrete, and mine reclamation materials, converting the environmental hazard into a valuable resource while reducing both environmental risk and accumulation quantities
Solution Approach 2:
The patent changes the physical and chemical parameters of CCR through encapsulation with binders and additives. This transformation modifies the material properties to reduce leaching potential and enable structural applications, allowing CCR to transition from a disposal problem to a construction solution
2Quantity of substance
If high percentages of CCR are used as cement replacements in structural materials, then natural resource conservation and cost-effectiveness are improved, but material strength and durability may be compromised
Solution Approach 1:
The patent creates composite materials by combining CCR with binders (such as cement, lime, or other binding agents) and additives. This composite approach allows high percentages of CCR (50-90% by weight) to be used while maintaining structural integrity through the synergistic interaction between CCR particles and the binding matrix
Solution Approach 2:
The patent applies local quality by using different binder types and ratios in different applications based on specific strength requirements. Load-bearing walls use optimized mix designs with specific binder contents, while non-structural applications can use higher CCR percentages, allowing tailored performance for each application
3Adaptability or versatility
If encapsulated CCR mixes are used in load-bearing structures, then environmental compliance and resource utilization are improved, but manufacturing complexity and quality control requirements increase
Solution Approach 1:
The patent establishes specific parameter ranges for encapsulated CCR mixes, including binder content (10-50% by weight of CCR), water-to-binder ratios, and additive dosages. These standardized parameter specifications simplify quality control and manufacturing while ensuring environmental compliance and structural performance across different applications
Solution Approach 2:
The patent creates a universal encapsulated CCR mix system that can be applied across multiple construction applications (load-bearing walls, concrete, mine reclamation) with minor adjustments to mix proportions. This universal approach reduces manufacturing complexity by using a core formulation that adapts to different uses rather than requiring entirely separate systems for each application
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The encapsulated CCR mixes provide a cost-effective, environmentally friendly solution for utilizing CCR in structural applications, meeting regulatory standards by ensuring reduced leaching and increased durability, thus transforming a waste material into a valuable resource for construction and remediation projects.
Implementation Method 1
coal combustion residuals ("CCR") mixed with water and a binder to form a structural material
Implementation Method 2
encapsulated CCR mixes provide a cost-effective, environmentally friendly solution for utilizing CCR in structural applications, meeting regulatory standards by ensuring reduced leaching
Data Source
AI summary
Beneficial use structures are disclosed that include coal combustion residuals (“CCR”) mixed with water and a binder to form a structural material, and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses are described, including compressed air storage facilities and a pumped hydroelectric facility, including such a facility adapted for use with a lock system of a waterway.